Container, packaging, and method for producing same

ABSTRACT

A container comprises a plant based structural layer having an inner surface and an opposed outer surface, and a pre-formed polymeric liner layer secured to the plant based structural layer and lining at least one of the inner surface and the outer surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/502,667 filed on Feb. 8, 2017, which is a national stage entry ofInternational Patent Application No. PCT/CA2015/050785 filed on Aug. 19,2015, which claims the benefit of U.S. Provisional Patent ApplicationNo. 62/045,050 filed Sep. 3, 2014, and U.S. Provisional PatentApplication No. 62/167,981 filed May 29, 2015. Each of theaforementioned patent applications is incorporated herein by referencein its entirety.

FIELD

The specification relates to containers and packaging, such as for foodor cosmetics. More particularly, the specification relates to containersand packaging that include two or more layers of material, and tomethods for producing such containers and packaging.

BACKGROUND

U.S. Pat. No. 6,200,644 (Ulfstedt et al.) purports to disclose methodsfor manufacturing liquid-tight and gas-tight packaging board, and apackage and products provided according to the said methods. Accordingto the invention, a polymerizing reaction mixture is spread on paper ora board base of paperboard or cardboard, the mixture containing at leastone silicon compound forming an inorganic, chain or cross-linkedpolymeric backbone containing alternating silicon and oxygen atoms, andat least one reactive, organic compound forming organic side chainsand/or crosslinks in the polymeric backbone. The reaction mixture mayform a colloidal solution in which, along with the polymerization,gelling takes place, whereupon the thus created gel is dried, densifiedand cured to form a liquid-tight and gas-tight layer of coating. Inaddition to oxygen and silicon, the said chain-like or cross-linkedpolymeric backbone can contain metal atoms which replace the silicon,and the organic compound can contain, as a reactive group, an epoxy, anamino, a carboxyl, a carbonyl, a vinyl or a methacrylate group.Furthermore, a joint-forming polymeric coating can be spread on thepreviously obtained, tight glassy layer of coating to close themanufactured package. Products, to which the paper or the board coatedaccording to the invention can be applied, include milk and juicecontainers or similar packages of liquid foodstuffs, bag-type foodstuffpackages, heat-sealed, peelable covers of containers and boxes, andmicrowave and conventional oven trays.

SUMMARY

The following summary is intended to introduce the reader to variousaspects of the specification, but not to define or delimit anyinvention.

According to some aspects, a package comprises a container including aplant based first structural layer having a first inner surface and anopposed first outer surface, and a pre-formed polymeric first linerlayer secured to the first structural layer and lining at least aportion of the first inner surface or the first outer surface. A lid isremovably securable to the container and comprises a plant based secondstructural layer having a second inner surface and an opposed secondouter surface, and a pre-formed polymeric second liner layer secured tothe second structural layer and lining at least a portion of the secondinner surface or the second outer surface.

In some examples, the first liner layer may be removably secured to thefirst structural layer, and the second liner layer may be removablysecured to the second structural layer. The first and second linerlayers may be secured to the first and second structural layers,respectively, with an adhesive. The first and second liner layers mayalternatively or additionally be mechanically secured to the first andsecond structural layers, respectively.

In some examples, the first liner layer may line the first innersurface. The first structural layer may comprise a base and a firstsidewall extending upwardly from the base, and may define a firstopening. The first sidewall may have an upper end defining the firstopening, and comprising an upper end face. The first liner layer maycomprise an overlap portion that includes a radially extending lipextending across the upper end face, and a downwardly extending firstskirt extending along a portion of the first outer surface.

In some examples, a separately formed first collar is provided forthreadably securing the lid to the container. The first collar may bereceived around the overlap portion of the first liner layer, and mayhave a threaded outer circumference for mating with the lid.

In some examples, the first skirt may have a plurality of aperturesextending through a wall thickness thereof, and the first collar may beadhered to the first structural layer via the apertures.

In some examples, the second liner layer may line the second innersurface. The second structural layer may comprise a top wall and adownwardly extending second side wall, and may define a second opening.The second liner layer may comprise a downwardly extending second skirt.A separately formed second collar may be provided for threadablysecuring the lid to the container. The second collar may be received inthe second skirt, and may have a threaded inner circumference for matingwith the container. The second skirt may have a plurality of aperturesextending through a wall thickness thereof, and the second collar may beadhered to the second structural layer via the apertures

In some examples, the first structural layer may include a first sidepiece, and a separately formed second side piece. Each side piece maycomprise a base portion and a sidewall portion. Each sidewall portionmay comprise a pair of generally vertically extending end faces, and apair of radially extending structural layer flanges adjacent the endfaces. The first liner layer may comprise a pair of liner layer flangesextending radially outwardly therefrom. Each liner layer flange may besandwiched between one of the structural layer flanges of the first sidepiece and one of the structural layer flanges of the second side piece.The liner layer flanges may comprise a plurality of apertures extendingthrough a wall thickness thereof, and the structural layer flanges ofthe first side piece may be adhered to the structural layer flanges ofthe second side piece via the apertures.

In some examples, the first liner layer may comprise a tongue, and thefirst structural layer may comprise a groove, and the tongue may bereceived in the groove and be frictionally secured therein.

In some examples, at least one of the first liner layer and the secondliner layer may be fabricated from silicone.

In some examples, at least one of the first structural layer and thesecond structural layer may be fabricated from bagasse.

According to some aspects, a container comprises a plant basedstructural layer having an inner surface and an opposed outer surface. Apre-formed polymeric liner layer is secured to the plant basedstructural layer and lines at least one of the inner surface and theouter surface.

In some examples, the structural layer may comprise a pair of flexiblepanels. Each panel may have a pair of opposed side edges, and the pairof panels may be joined to each other along the side edges. Thecontainer may reconfigurable between a flattened configuration in whichthe panels are flattened to provide a substantially flat container, andan expanded configuration in which the panels are flexed outwardly todefine an interior volume of the container therebetween.

In some examples, the container may further comprise at least one endcap to retain the container in the expanded configuration.

In some examples, the liner layer may be removably secured to thestructural layer.

In some examples, the container may further comprise a liquid-permeablefilter media positioned interior of the structural layer. The pre-formedpolymeric liner layer may comprise a first liner layer lining the outersurface, and a second liner layer secured to at least one of thestructural layer and the first inner layer and sealing the filter mediawithin a volume defined by the inner surface of the structural layer andthe second liner layer.

In some examples, the container may further comprise a thread secured ata first end to the filter media. A second end of the thread may begraspable by a user. The filter media may be separable from thestructural layer by pulling on the second end while restraining thestructural layer.

In some examples, the first end of the thread is secured about aperimeter of an upper end of the filter media.

In some examples, the first end of the thread is also secured about aperimeter of the second liner layer.

In some examples, the second liner layer, the filter media, and thethread are compostable.

In some examples, the liner layer may be secured to the structural layerwith an adhesive. In some examples, the liner layer may be mechanicallysecured to the structural layer.

In some examples, the liner layer may be fabricated from silicone. Insome examples, the structural layer may be fabricated from bagasse.

According to some aspects, a process for making a container comprises a)forming a structural layer of the container from a plant based material;b) separately forming a liner layer of the container from a polymer, toyield a pre-formed liner layer; c) mating the pre-formed liner layer tothe structural layer, so that the pre-formed liner layer lines at leasta portion of the structural layer; and c) securing the pre-formed linerlayer to the structural layer.

In some examples, step c) may comprise inserting the pre-formed linerlayer into the structure layer. In some examples, step c) may compriseinserting the structural layer into the pre-formed liner layer.

In some examples, step d) may comprise removably securing the pre-formedliner layer to the structural layer.

In some examples, the process may further comprise: e) removing thepre-formed liner layer from the structural layer, and recycling each ofthe pre-formed liner layer and the structural layer.

In some examples, step d) may comprise positioning a portion of thepre-formed liner layer between two portions of the structural layer.

In some examples, the process may further comprise pinching the portionof the pre-formed liner layer between the two portions of the structurallayer to frictionally secure the pre-formed liner layer to thestructural layer. The portion of the pre-formed liner layer may includeapertures extending therethrough, and the process may further compriseadhering the two portions of the structural layer together via theapertures.

In some examples, the process may further comprise securing a threadedcollar over the liner layer. Step c) may comprise positioning an overlapportion of the pre-formed liner layer on an outer surface of thestructural layer, and step d) may comprise positioning the threadedcollar over the overlap portion. The overlap portion may includeapertures extending therethrough, and step d) may comprise adhering thethreaded collar to the structural layer via the apertures.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the present specification and arenot intended to limit the scope of what is taught in any way. In thedrawings:

FIG. 1 is a side elevation view of an example package, with a lid of thepackage secured to a container of the package;

FIG. 2 is a side elevation view of the package of FIG. 1, with the lidremoved from the container;

FIG. 3 is an exploded perspective view of the package of FIG. 1;

FIG. 4 is a cross-section taken along line 4-4 in FIG. 2;

FIG. 5A is a side elevation view of another example container, in apartially unassembled configuration;

FIG. 5B is a side elevation view of the container of FIG. 5A, in anassembled configuration;

FIG. 6A is a cross-section taken along line 6A-6A in FIG. 5A;

FIG. 6B is a cross-section taken along line 6B-6B in FIG. 6B;

FIG. 7 is a side elevation view of another example package, with a lidof the package secured to a container of the package;

FIG. 8 is a side elevation view of the package of FIG. 7, with the lidremoved from the container;

FIG. 9 is a cross-section taken along line 9-9 in FIG. 7;

FIG. 10 is an exploded view of the container of FIG. 7;

FIG. 11 is a perspective view of another example package;

FIG. 12 is a cross-section taken along line 12-12 in FIG. 11;

FIG. 13 is the cross-section of FIG. 12, with a structural layer of thelid and a liner layer of the lid removed from the container;

FIG. 14 is a cross-section showing an alternative package;

FIG. 15A is a cross-sectional view of a structural layer of anotherexample package;

FIG. 15B is a cross-sectional view of the structural layer of FIG. 15A,with a liner layer positioned partially interior of the structurallayer;

FIG. 15C is a cross-sectional view of the structural layer of FIG. 15A,with the liner layer of FIG. 15B positioned interior of the structurallayer, and with an outer layer positioned partially exterior of thestructural layer;

FIG. 15D is a cross-sectional view of the structural layer of FIG. 15A,with the liner layer of FIG. 15B positioned interior of the structurallayer, and with the outer layer of FIG. 15C positioned exterior of thestructural layer;

FIG. 15E is a cross-sectional view of the structural and liner layers ofFIG. 15D, with the liner layer in a sealed configuration at one end ofthe container, and with the outer liner layer in a sealed configurationat the other end of the structural layer;

FIG. 16 is a perspective view of another example container;

FIG. 17A is a perspective view of another example container in apartially unassembled configuration;

FIG. 17B is a perspective view of the container of FIG. 17A, in anassembled configuration; and

FIG. 18 is a cross-sectional view of another example container with aplurality of outer layers positioned on the exterior of the container.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide anexample of an embodiment of each claimed invention. No embodimentdescribed below limits any claimed invention and any claimed inventionmay cover processes or apparatuses that differ from those describedbelow. The claimed inventions are not limited to apparatuses orprocesses having all of the features of any one apparatus or processdescribed below or to features common to multiple or all of theapparatuses described below. It is possible that an apparatus or processdescribed below is not an embodiment of any exclusive right granted byissuance of this patent application. Any invention disclosed in anapparatus or process described below and for which an exclusive right isnot granted by issuance of this patent application may be the subjectmatter of another protective instrument, for example, a continuingpatent application, and the applicants, inventors or owners do notintend to abandon, disclaim or dedicate to the public any such inventionby its disclosure in this document.

The present application relates to packaging for a variety of materials.Such materials may include, but are not limited to, food, drinks, water,chemicals, cosmetics, soaps, medicines, and detergents. The packagingdisclosed herein may in some examples be generally waterproof. In someexamples, the interior of the package may be waterproof, in that it mayprevent liquids or wet materials from leaking out from the package. Suchpackages may optionally be used to store liquids, pastes, gels, or otherwet materials. However, such packaging may also be used to storegenerally dry materials. In some examples, the exterior of the packagemay be waterproof, in that it may prevent or inhibit wet materials fromentering the package. For example, such a package may optionally be usedto store dry materials, and to prevent such materials from becoming wet.Furthermore, the packaging disclosed herein may in some examples begenerally reusable and/or recyclable. Furthermore, the packagingdisclosed herein may in some examples be made from materials that areconsidered generally environmentally friendly, such as plant fibers(e.g. bagasse) and silicone polymers.

In general, examples of the packaging disclosed herein may emulate thedesirable properties of plastic packaging by using one or more plantfiber layers or shells to provide structural support and/or rigidity,and one or more polymeric layers (e.g. silicone polymer) to provide aliquid impermeable barrier to contain a liquid within the packaging(and/or to prevent liquid from entering the packaging), and/or toprotect the one or more plant fiber layers from exposure to liquids. Inthis way, the packaging disclosed herein may in some examples be used asa replacement for or as an alternative to plastic containers andpackages. For example, the packaging disclosed herein may be used as analternative to plastic water bottles.

Referring now to FIGS. 1 and 2, an example package 100 is shown. Thepackage is generally in the configuration of a jar, and includes acontainer 102, and a lid 104 removably secured to the container 102. Inthe example shown, the lid 104 may be secured to the container byscrewing the lid 104 onto the container 102, and may be removed from thecontainer 102 by unscrewing the lid 104 from the container 102, as shownin FIG. 2.

In alternative examples, the lid may be secured to the container inanother manner, for example by a snap fit, bayonet mount, or frictionfit with the container.

In the example shown, the lid 104 may be re-secured to the container 102after it has been removed. In alternative examples, the lid andcontainer may be configured such that the lid may generally not besecured back onto the container after it has been removed. For example,the lid may be adhered to the container so that it must be torn to beremoved from the container.

Referring now to FIGS. 3 and 4, each of the container 102 and the lid104 include a structural layer 106, 108, respectively, and a liner layer110, 112, respectively. The liner layers 110, 112 serve to line at leasta portion of the structural layers 106, 108, respectively. Thestructural layer 106 of the container 102 may also be referred to hereinas a “first structural layer”, and the structural layer 108 of the lid104 may also be referred to herein as a “second structural layer”. Theliner layer 110 of the container 102 may also be referred to herein as a“first liner layer”, and the liner layer 112 of the lid 104 may also bereferred to herein as a “second liner layer”.

The structural layers 106, 108 may in some examples be plant based. Forexample, the structural layers 106, 108 may be made from a paperboardand/or cardboard. The plant material used for the structural layer maybe derived from, for example, rice, wheat, wood, cotton, flax, linen,sugarcane, bamboo, kenaf, hemp, cork, coconut, jute, and combinationsthereof. For example, the plant material may be wood fiber, cottonfiber, flax fiber, linen fiber, bagasse fiber, bagasse husks, bagassestraw, bamboo fiber, kenaf fiber, hemp fiber, coconut coir, jute fiber,and combinations thereof. In some examples, the plant material may be awaste material, such as rice chaff or husks. In some examples, the plantmaterial may be purpose grown. In some examples, the plant material maybe virgin materials. In some examples, the plant materials may berecycled materials. In some examples, non-plant based additives may beincluded in the structural layer, such as calcium carbonate. In someparticular examples, the structural layers 106, 108 may be fabricatedfrom bagasse, and may include bagasse fiber paperboard. Alternatively oradditionally, the structural layer may include natural latex.

The structural layers 106, 108 may in some examples include fibers ofdifferent coarseness, different refinements, and varying levels ofprocessing.

The structural layers 106, 108 may optionally be formed by molding. Thestructural layers 106, 108 may have a wall thickness that is selectedbased on the structural strength required of the package.

The liner layers 110, 112 may in some examples be generally waterproof,antimicrobial, and/or inert. The liner layers 110, 112 may also in someexamples be oxygen impermeable, and impermeable to other gases. In someexamples, the liner layers 110, 112 may be polymeric, and in someparticular examples are fabricated from a silicone polymer, such as afood grade silicone polymer. Alternatively or additionally, the linerlayers 110, 112 may be or may include another polymeric material, suchas latex, or a bioplastic such as a plant based polymer. One example ofsuch a bioplastic is a thermoplastic starch polymer. Another example ofsuch a bioplastic is an algae-based plastic. Alternatively oradditionally, the liner layers 110, 112 may be or may include a sugarbased polymer. Alternatively or additionally, the liner layers 110, 112may be or may include conventional polymers, such as polyethylene.

The liner layers 110, 112 may be pre-formed. That is, they may be formedinto a particular shape (e.g. by molding, or by joining sheets byadhesives, heat, or sonic welding) and then subsequently mated to thestructural layers 106, 108. For example, the pre-formed liner layers110, 112 may be inserted into and secured to the structural layers 106,108, respectively. In alternative examples, liner layers may be formedinto a particular shape, and then the structural layers may be insertedinto the liner layers. These examples, wherein the liner layers arepre-formed, are in contrast to processes wherein a polymeric layer isformed directly on a paperboard layer by a coating process, and the term“pre-formed” excludes such processes.

As used herein, the term “secured” indicates that the liner layers 110,112 are held together with the structural layers 106, 108, respectively,in such a manner so that the liner layers 110, 112 do not come apartfrom the structural layers 106, 108 during use of the packaging to storeand dispense a material. That is, if the container 102 is inverted todispense the contents thereof, the liner layer 110 will not fall out ofthe structural layer 106 under the force of gravity. Similarly, if thelid 104 is inverted, the liner layer 112 will not fall out of thestructural layer 108 under the force of gravity. The term “removablysecured” indicates that the liner layers 110, 112 are held together tothe structural layers 106, 108, respectively, in such a manner so thatthe liner layers 110, 112 do not come apart from the structural layers106, 108 during use of the packaging to store and dispense a material;however, the liner layers 110, 112 may be separated from the structurallayers 106, 108 if additional force is applied, such as if the packageis crushed or if the liner layers 110, 112 are torn from the structurallayers 106, 108.

The liner layers 110, 112 may optionally be relatively thin. Thinnerliner layers may be advantageous in order to minimize the amount ofsilicon used in the package. For example, the liner layers 110, 112 mayhave a wall thickness of as low as 0.025 mm. In some particularexamples, the liner layers 110, 112 may have a wall thickness of betweenabout 0.025 mm and about 0.127 mm. In further particular examples, theliner layers 110, 112 may have a wall thickness of between about 0.025mm and about 0.05 mm.

The use of pre-formed liner layers 110, 112 may in some examples beadvantageous, because this may allow for the liner layers 110, 112 to beremovably secured to the structural layers 106, 108 respectively. Thismay allow for the liner layers 110, 112 to be removed from thestructural layers 106, 108, respectively, for recycling or composting.For example, after the package 100 has been used (e.g. after a singleuse or multiple uses), the liner layers 110, 112 may be removed from thestructural layers 106, 108, and each may be separately recycled, or thestructural layers 106, 108 may be composted. The liner layers 110, 112may be removed from the structural layers 106, 108 manually, or in anautomated process. For example, an end-user (e.g. a consumer of a foodproduct in the package) may manually separate the liner layers 110, 112from the structural layers and place each in a recycling bin or compostbin. Alternatively, the liner layers 110, 112 may be separated from thestructural layers 106, 108 at a recycling facility, either manually orby machine. In either case, in order to facilitate the removal of theliner layers 110, 112 from the structural layers 106, 108, the package100 may optionally first be crushed prior to removal of the liner layers110, 112.

Referring still to FIGS. 3 and 4, the configuration of the container 102will be described in further detail.

In the example shown, the container 102 is generally cylindrical, andthe structural layer 106 of the container 102 includes a circular base114 and a generally cylindrical sidewall 116 (also referred to as a“first sidewall”) extending upwardly from the base 114. The structurallayer 106 further defines an opening 118 (also referred to as a “firstopening”).

In alternative examples, the container 102 may be of another shape, forexample generally cubic. In such an example, the sidewall 116 mayinclude four generally square sidewall portions. In other examples, thecontainer 102 may be of a non-fixed shape.

The structural layer 106 has an inner surface 120 (also referred to as a“first inner surface”) and an opposed outer surface 122 (also referredto as a “first outer surface”). In the example shown, the liner layer110 is secured to the structural layer 106 and lines the inner surface120. Specifically, the liner layer 110 includes a generally circularbottom panel 121 that lines the base 114, and a generally cylindricalside panel 123 that lines the sidewall 116. In the example shown, theliner layer 110 is one single integral piece.

In the example shown, the liner layer 110 lines the entirety of theinner surface 120. In alternative examples, the liner layer 110 may lineonly a portion of the inner surface 120.

As mentioned above, in the example shown, the liner layer 110 isremovably secured to the structural layer 106, as will be described infurther detail below. In general, liner layers may be removably securedto structural layers for example with an adhesive, and/or may bemechanically removably secured to the structural layers.

As an example of mechanical securement, a liner layer may be positionedbetween multiple structural layers (or multiple portions of a structurallayer) to create a frictional hold on the liner layer entrapped betweenthe structural layers. As another example of mechanical securement, thestructural layer at the rim of a container opening may be rolled onto oralong with a liner layer to secure the liner layer within the rolledstructural layer. In some examples, some or all of the surface of theliner layer and/or the folded fiber layers may be shaped and/or textured(e.g. provided with teeth, ridges or the like) to increase thefrictional grip between the secured layers. Examples of mechanicalsecurement are described in further detail below.

In the case of an adhesive, a liner layer may be removed from astructural layer for example by tearing the liner layer away from thestructural layer. In case of mechanical securing, a liner layer may beremoved from a structural layer for example by tearing the liner layeraway from the structural layer, or by removing or undoing the mechanicalsecuring mechanism.

In the example shown, the sidewall 116 has an upper end 124 that definesthe first opening 118, and that includes an upper end face 126. Theliner layer 110 includes an overlap portion 128 that includes a radiallyextending lip 130 that extends across the upper end face 126, and adownwardly extending skirt 132 that extends along a portion of the outersurface 122. The overlap portion 128 forms a pocket that receives theupper end 124 of the sidewall 116, and frictionally grips the sidewall116.

Furthermore, in the example shown, the container 102 further includes acollar 134 (also referred to as a “first collar”). The collar 134 isreceived around the overlap portion 128 of the liner layer 110. Theskirt 132 has a plurality of apertures 135 extending through its wallthickness. An adhesive is applied to the apertures 135 and is used tosecure the collar 134 to the upper end 124 of the sidewall 116, via theapertures 135. More specifically, the adhesive may be applied to theouter surface 122 at upper end 124, to the skirt 132, and/or to thecollar 134. The adhesive may generally fill the apertures 135, so thatthe collar 134 is adhered to the structural layer 106 through theapertures. The collar 134 therefore further secures the liner layer 110to the structural layer 106.

In the example shown, the collar 134 is threaded. That is, the collar134 has a threaded outer circumference 136, for mating with the lid 104,as will be described in further detail below.

The collar 134 may be, for example, plant based, as described above withrespect to the structural layers 106, 108. For example, the collar 134may be made from a paperboard or cardboard, may include any of the plantfibers described above, and may be molded.

Referring still to FIGS. 3 and 4, the configuration of the lid 104 willbe described in further detail.

In the example shown, the lid 104 is generally cylindrical to match theshape of the container 102, and the structural layer 108 of the lid 104includes a generally circular top wall 138, and a generally cylindricaldownwardly extending sidewall 140 (also referred to as a “secondsidewall”). The structural layer 108 further defines an opening 142(also referred to as a “second opening”). The structural layer 108includes an inner surface 144 (also referred to as a “second innersurface”) and an opposed outer surface 146 (also referred to as a“second outer surface”).

In the example shown, the liner layer 112 of the lid 104 is secured tothe structural layer 108 and lines a portion of the inner surface 144.More specifically, the liner layer 112 includes a generally circular toppanel 148 that lines the top wall 138, and a downwardly extending skirt150 that lines a portion of the sidewall 140. In alternative examples,the liner layer 112 may line the entire inner surface 144.

As mentioned above, the liner layer 112 may removably secured to thestructural layer 108. For example, as mentioned above, liner layers maybe removably secured to structural layers with an adhesive, and/or maybe mechanically removably secured to structural layers. In the case ofan adhesive, liner layers may be removed from structural layers forexample by tearing the liner layer away from the structural layer. Incase of mechanical securing, liner layers may be removed from structurallayers for example by tearing the liner layer away from the structurallayer, or by removing or undoing the mechanical securing mechanism.

In the example shown, the lid 104 further includes a second collar 152.The second collar 152 is received in the skirt 150 of the liner layer112. The skirt 150 has a plurality of apertures 155 extending throughits wall thickness. An adhesive is applied to the apertures 155 and isused to secure the second collar 152 to the sidewall 140 of thestructural layer 108 via the apertures 155. The adhering of the secondcollar 152 to the sidewall 140 secures the liner layer 112 to thestructural layer 108.

In the example shown, the second collar 152 is threaded. That is, thesecond collar 152 has a threaded inner circumference 154. The lid 104may be secured to the container 102 by engaging the threads of thesecond collar 152 with the threads of the first collar 134, andtightening. When tightened, the top panel 148 of the liner layer 112 ofthe lid 104 may be pressed and sealed against the lip 130 of the linerlayer 110 of the container 102, to form a generally watertight sealbetween the lid 104 and the container 102.

In alternative examples, the collars 134, 152 may serve only to securethe liner layers 110, 112 to the structural layers 106, 108,respectively, and may not necessarily be threaded for securing the lid104 to the container 102. In some such examples, an alternativemechanism may be provided for securing the lid 104 to the container 102.For example, the lid 104 may be adhered to the container 102. In furtheralternative examples, the collars 134, 152 may serve only to secure thelid 104 to the container 102, and may not necessarily aid in securingthe liner layers 110, 112 to the structural layers 106, 108. In somesuch examples, the liner layers 110, 112 may be secured to thestructural layers 106, 108, respectively, in another manner, such as byfriction. In yet further alternative examples the collars 134, 152 maynot be threaded, and may secure the lid 104 to the container 102 inanother manner. For example, the collars 134, 152 may be configured tosecure the lid 104 to the container 102 by a snap-fit, a friction fit,or a bayonet mount.

Referring now to FIGS. 5A to 6B, an alternative example of a container502 is shown. In FIGS. 5A to 6B, like features as in FIGS. 1 to 4 arereferred to with like reference numerals, with the first digitincremented by 4.

In this example, an additional securing mechanism is provided to securethe liner layer 510 of the container 502 to the structural layer 506 ofthe container 502. More specifically, the sidewall 516 of the structurallayer is formed in two pieces, 516 a, 516 b, that may be folded towardseach other, as shown in FIGS. 5B and 6B, and away from each other, asshown in FIGS. 5A and 6A. The junction between the sidewall pieces 516a, 516 b, respectively, and the base 514 includes a groove 556. When thesidewall pieces 516 a, 516 b are folded away from each other, the groove556 is generally open, and when the sidewall pieces 516 a, 516 b arefolded towards each other, the groove 556 is generally closed.

The liner layer 510 includes a tongue 558, extending downwardly from theperimeter of the bottom panel 521. During manufacturing of the container502, the tongue 558 may be positioned in the groove 556 when the groove556 is open. The sidewall pieces 516 a, 516 b may then be folded towardseach other, to close the groove 556 and pinch and frictionally securethe tongue 558 in the groove 556. The sidewall pieces 516 a, 516 b maythen be secured together, for example with the use of an adhesive. Theoverlap portion 528 of liner layer 510 may then be positioned over andsecured to the upper end 524 of the structural layer 506, as describedabove.

In the example of FIGS. 5A to 6B, the tongue 558 may optionally includeapertures (not shown), so that the opposed surfaces of the groove 556can be adhered together via the apertures.

In the example of FIGS. 5A to 6B, the container 502 may optionallyinclude a collar (not shown) as described above with respect to FIGS. 1to 4.

Referring now to FIGS. 7 to 10, another alternative example of acontainer 702 is shown. In FIGS. 7 to 10, like features as in FIGS. 1 to4 are referred to with like reference numerals, with the first digitincremented by 6.

In the example shown, the structural layer 706 of the container 702 isformed in two separate pieces, including a first side piece 706 a, and asecond side piece 706 b. Each sidepiece 706 a, 706 b, includes asemi-circular base portion (not shown), and a semi-cylindrical sidewallportion 716 a, 716 b, respectively.

In the example shown, the first sidewall portion 716 a includes a pairof generally vertically extending end faces 760 a, 762 a, and a pair ofradially extending flanges 764 a, 766 a (also referred to as “structurallayer flanges”) adjacent the end faces 760 a, 762 a. Similarly, thesecond sidewall portion 716 b includes a pair of generally verticallyextending end faces 760 b, 762 b, and a pair of radially extendingflanges 764 b, 766 b (also referred to as “structural layer flanges”)adjacent the end faces 760 b, 762 b.

The liner layer 710 includes a pair of flanges 765, 767 (also referredto as “liner layer flanges”) extending radially outwardly from thecylindrical side panel 723. The liner layer flanges 765, 767 include aplurality of apertures 735 extending through a wall thickness thereof.

Each liner layer flange 765, 767 is sandwiched between a flange of thefirst side piece 706 a and the second side piece 706 b. Specifically,the flange 765 is sandwiched between the flanges 764 a and 764 b, andthe flange 767 is sandwiched between the flanges 766 a, 766 b. Theflanges 764 a and 764 b are adhered together via the apertures 735 inthe flange 765, and the flanges 766 a and 766 b are adhered together viathe apertures in the flange 767.

Referring now to FIGS. 11 and 13, a further alternate example of apackage 1100 is shown. In FIGS. 11 and 13, like features as in FIGS. 1to 4 are referred to with like reference numerals, with the first digitincremented by 10.

In the example shown in FIGS. 11 to 13, the container 1102 and lid 1104are generally rectangular, and the container includes a plurality ofcompartments 1170 a, 1170 b, 1170 c. Such a container may be useful, forexample, for pre-prepared meals, such as pre-prepared frozen meals orpre-prepared microwave meals.

Furthermore, in this example, the container 1102 and lid 1104 areconfigured to be opened only a single time, and are not configured to bereadily re-sealed back together. Specifically, the liner layer 1110 ofthe container 1102 and the liner layer 1112 of the lid 1104 each have astrip 1172, 1174 (labeled in FIG. 13), respectively, molded therein. Thestrips 1172, 1174 may be, for example, foil strips or paper strips. Thestrips 1172, 1174 extend around the perimeter of the container 1102, andbetween the compartments 1170 a-c, and are positioned to contact eachother when the lid 1104 is positioned on the container 1102. The strips1172 may be adhered to the strips 1174 with an adhesive, for example athermal adhesive.

In the example shown, the support layer 1108 of the lid 1104 includes anintegral collar 1134. The integral collar 1134 extends downwardly overthe skirt 1132 of the liner layer 1110 of the container 1102, and isadhered to the support layer 1106 of the container 1102 via apertures1135 in the skirt 1132.

In one or more alternative examples, a support layer 1108 may not beprovided, and liner layer 1112 may be adhered to container 1102. Such acontainer may be characterized as a blister pack, in which compartments1170 a, 1170 b, 1170 c may be opened separately by piercing or otherwiseremoving the portion of liner layer 1112 overlying the compartment to beopened. In some examples, liner layer 1112 may be translucent ortransparent (e.g. a transparent silicone layer) to allow the contents ofcompartments 1170 a, 1170 b, 1170 c to be viewed without opening thecompartments.

In the example shown, the remainder of the support layer 1108 isseparable from the collar 1134. Particularly, a perforated line 1176 isformed between the collar 1134 and the remainder of the support layer1108, so that the remainder of the support layer 1108 may be torn fromthe collar 1134. The remainder of the support layer 1108 may include atab or handle 1178, to aid in tearing.

In some examples, in order to open the package 1100, the user may firsttear the remainder of the support layer 1108 off of the container 1102,by grasping the handle 1178 and pulling, to cause the support layer 1108to tear along the perforated line 1176 and lift off of the container1102. This leaves the collar 1134 in place on the container 1102.

The user may then grasp the liner layer 1112 of the lid 1104 (which mayalso optionally be provided with a handle), and pull it away from thecontainer 1102. This pulling may cause the strips 1172, 1174 to separatefrom each other, and open the package 1100.

The package 1100 of FIGS. 11 to 13 may optionally be used in order topreserve food. For example, the pre-formed liner layer 1110 of thecontainer 1102 may be filled with food prior to being inserted in thesupport layer 1106. In some examples, particularly where the liner layer1110 is relatively thin and unable to hold its shape when filled withfood, a carrier may be used to support the liner layer 1110. Forexample, the liner layer 1110 may be nested in a stainless steel trayhaving the same shape as the liner layer 1110. The filled liner layer1110 may then be sealed with the pre-formed liner layer 112 of the lid1104. The filled and sealed liner layers 1110, 1112 may then beprocessed according to traditional canning methods to preserve thecontents. For example, the filled and sealed liner layers 110, 112 maybe heated. The liner layers 1110, 1112 may then be inserted into andassembled to the support layer 1106 of the container 1102, and thesupport layer 1108 of the lid 1104 may be mounted to the container 1102and adhered thereto.

The package 1100 of FIGS. 11 to 13 may be modified to include anothernumber of compartments. For example, the package may include a singlecompartment only. The single compartment may be used, for example, tostore and preserve food (e.g. soup), as described above.

Referring now to FIG. 14, a further alternate example of a package 1400is shown. In FIG. 14, like features as in FIGS. 1 to 4 are referred towith like reference numerals, with the first digit incremented by 13.

In the package 1400, the lid 1404 is secured to the container 1402 by afriction fit. The liner layer 1410 includes a series of radiallyinwardly extending flanges 1480. The structural layer 1408 of the lid1404 includes a downwardly extending plug 1482, and the liner layer 1412of the lid 1404 lines the plug 1482. The liner layer 1412 of the lid1404 includes a plurality of radially outwardly extending flanges 1484extending around the plug 1482. In use, the plug 1482 may be pressedinto the opening 1418, so that the flanges 1484 of the lid 1404 snappast the flanges of the container 1402. When the plug 1482 is fullypressed into the opening 1418, the flanges 1484 of the lid may bepositioned between the flanges 1480 of the container. This engagement ofthe flanges 1480, 1484, as well as the relatively snug fit of the plug1482 into the opening 1418, may seal the lid 1404 to the container 1402.

In the example shown, the liner layer 1412 of the lid 1404 is secured tothe structural layer 1408 of the lid by an adhesive. However, inalternative examples, the liner layer 1412 may be secured to thestructural layer 1408 of the lid by an adhesive in another manner, suchas with a collar (not shown).

Referring now to FIGS. 15A to 15E, an alternative example of a container1502 is shown. In FIGS. 15A to 15E, like features as in FIGS. 1 to 4 arereferred to with like reference numerals, with the first digitincremented by 14.

Referring to FIG. 15A, in this example, the structural layer 1506includes a sidewall 1516 that defines an opening 1518 b at a lower endof the sidewall. Sidewall 1516 also includes a neck portion 1570 at theupper end 1524 of the sidewall 1516 that defines an opening 1518 a.

Referring to FIG. 15B, in the example shown, container 1502 includes aliner layer 1510 dimensioned to be inserted into and to line the innersurface 1520 of the structural layer 1506. Liner layer 1510 includes atongue 1558, extending downwardly from the perimeter of its bottom panel1521. Liner layer 1510 also includes an overlap portion 1528 dimensionedto be inserted through and abut the inner surface of neck portion 1570.As shown in FIG. 15B, during manufacturing of the container 1502, linerlayer 1510 can be positioned interior of structural layer 1506 viaopening 1518 b.

Referring to FIG. 15C, in the example shown, container 1502 alsoincludes an outer liner layer 1590 dimensioned to be positioned over andto line the outer surface 1522 of the structural layer 1506. As shown inFIG. 15C, during manufacturing of the container 1502, outer liner layer1590 can be positioned about structural layer 1506 via an openingdefined by the lower portion of the generally cylindrical side panel1593 of outer layer 1590.

In FIG. 15D, liner layer 1510 has been positioned within structurallayer 1506, and outer liner layer 1590 has been positioned aboutstructural layer 1506. Layers 1510 and 1590 may be positioned relativeto structural layer 1506 in any order, or simultaneously.

As shown in FIG. 15E, the overlap portion 1528 may then be manipulatedand/or stretched during manufacturing to provide a radially extendinglip 1530 that extends across the upper end face 1526 of structural layer1506, and to also provide a downwardly extending skirt 1532 that extendsalong a portion of the outer surface 1592 of outer liner layer 1590.Overlap portion 1528 may be secured to outer liner layer 1590 and/or toneck portion 1570 of structural layer 1506, for example with the use ofan adhesive. In this way, inner layer 1510 and outer liner layer 1590may cooperate to provide a moisture-impermeable barrier surrounding theopening 1518 a.

Referring still to FIG. 15E, in the example shown, an overlap portion1594 (Shown in FIG. 15D) of outer liner layer 1590 may be manipulatedand/or stretched during manufacturing to provide a radially extendinglip 1531 that extends across a lower end face 1527 of structural layer1506, and to also provide an upwardly extending skirt 1533 that extendsalong a portion of the tongue 1558 of liner layer 1510. Overlap portion1594 may be secured to liner layer 1510 and/or to structural layer 1506,for example with the use of an adhesive. In this way, outer liner layer1590 and tongues 1558 of liner layer 1510 may cooperate to provide amoisture-impermeable barrier surrounding the opening 1518 b ofstructural layer 1506.

Referring still to FIG. 15E, in the example shown, a structural insert1514 is positioned within lower opening 1518 b to provide support forbottom panel 1521 of liner layer 1510, and/or to provide radial supportfor the lower portion of sidewall 1516 of structural layer 1506.Structural insert 1514 is dimensioned to be inserted into lower opening1518 b and to abut the tongue 1558 of liner layer 1510 and/or the skirt1533 of outer liner layer 1590. Optionally, at least the lower surfaceof structural insert 1514 may be provided with a moisture-impermeablelayer of coating.

In the example of FIGS. 15A to 15E, the container 1502 may optionallyinclude a collar (not shown) as described above with respect to FIGS. 1to 4, and/or a lid (not shown) as described above with respect to FIGS.1 to 4 or FIG. 14.

In some examples, container 1502 may be characterized as afully-immersible container, as the structural layer 1506 is protectedfrom moisture on its inner and outer surfaces. Such a container may beuseful, for example, for storing prolonged use consumables, such askitchen and bath products, and yard and auto care products, and/or inenvironments where contact with moisture is expected, such as a kitchencounter, a refrigerator, and/or a garden shed. Such a container mayemulate the properties of a typical plastic container, but may be morerecyclable and/or compostable, and/or may be otherwise regarded as amore environmentally friendly container.

Referring now to FIG. 16, an alternative example of a container 1602 isshown. In FIG. 16, like features as in FIGS. 1 to 4 are referred to withlike reference numerals, with the first digit incremented by 15.

In this example, the structural layer 1606 comprises a pair of panels1607. Panels 1607 are initially joined along a pair of edges 1609 a,b.This allows structural layer 1606 to be ‘flattened’ by positioningpanels 1607 in close proximity to each other. In such a ‘flat’ state,container 1602 may have a relatively compact and dense footprint (e.g.compared to an empty, rigid container such as a typical plastic waterbottle), which may be advantageous e.g. during shipping of an emptycontainer 1602. Accordingly, container 1602 may be characterized as a‘ships-flat’ container.

In some examples, container 1602 may be dimensioned to have an interiorvolume similar to that of a typical water bottle intended for personaluse (e.g. from about 250 mL to about 1.5 L), and to be graspable withone hand by a user. A container with such dimensions may becharacterized as a ‘ships-flat bottle’. Alternatively, container 1602may be dimensioned to have an interior volume similar to that of atypical beverage container intended for personal use (e.g. from about200 mL to about 300 or 500 mL), and to be graspable with one hand by auser. A container with such dimensions may be characterized as a‘ships-flat cup’. Alternatively, container 1602 may be relatively largeand have a relatively heavy structural layer 1606.

Prior to filling container 1602, the interior surfaces of structurallayer 1606 are provided with a liner layer 1610. Liner layer 1610 maydefine a watertight interior volume within structural layer 1606 (i.e.liner layer 1610 provides a sealed pouch within container 1602). Linerlayer 1610 may be provided prior to ‘flattening’ the structural layer1606, e.g. prior to shipping. Alternatively, liner layer 1610 may beprovided after ‘flattening’ the structural layer 1606, e.g. aftershipping.

The interior volume defined by liner layer 1610 may be shipped andstored in a sealed state and subsequently pierced during a fillingoperation, which may optionally be aseptic.

Before or after the interior volume defined by liner layer 1610 isfilled, one or more end caps 1614 may be positioned between the panels1607 of structural layer 1606. In FIG. 16, an example end cap 1614 isshown positioned at the upper end of structural layer 1606. Each end cap1614 provides shape to container 1602 by resisting inward and/or outwarddeflection of panels 1607 of structural layer 1606. In some examples,end caps 1614 may additionally provide support for liner layer 1610.

In some examples, one or more end caps 1614 may be joined to panels 1607during manufacturing (e.g. via a hinge or fiber strip), and may befolded or tucked between panels 1607 when structural layer is positionedin a ‘flat’ state. Optionally, end caps 1614 may be attached (e.g. viaan adhesive) to liner layer 1610 prior to filling the interior volumedefined by liner layer 1610. The end caps 1614 can be formed with one ormore creases to allow folding or expansion of container. Alternatively,the end caps 1614 can be rigid and non-foldable.

Container 1602 may be filled via a (aseptic capable) fill port (notshown) that may be accessible e.g. through an opening in bottom end cap1614. After filling of container 1602 (i.e. filling the interior volumeof liner layer 1610) and sealing of the fill port, the fill port may betucked inside container 1602 (e.g. between panels 1607 of structurallayer 1606), and a patch (e.g. a fiber patch) may be optionally appliedto cover any hole or other access opening in end cap 1614. Inalternative examples, the fill port may be in the top end cap.

Filling of the container 1602 (i.e. filling the interior volume of linerlayer 1610) will urge the panels 1607 of structural layer 1606 away fromeach other, which may be characterized as ‘inflating’ container 1602. Insome examples, the filling or inflating of container 1602 may also urgeone or more end caps 1614 that are attached to panels 1607 and/or linerlayer 1610 into an aligned position between panels 1607, at which timethe end caps 1614 may be further aligned (e.g. manually or via machine)into a final position. Once in the final position, end caps 1614 may besecured to one or both panels 1607 of structural layer 1606, e.g. usingan adhesive.

In some examples, end caps 1614 are made of plant fibers and havesufficient strength and/or rigidity to keep the panels 1607 of container1602 apart once the liner layer 1610 has been partially or fullyemptied.

In some examples, end cap 1614 and/or liner layer 1610 may have a tearopen feature to provide access to the interior volume of the container1602, e.g. for pouring or drinking. As shown in FIG. 16, a portion 1614a of end cap 1614 may be perforated or otherwise configured tofacilitate manual separation of a portion of end cap 1614 and/or panels1607 of structural layer 1606.

In some examples, the fill port may be configured to provide access tothe interior volume of a filled container 1602, e.g. for pouring ordrinking. In some examples, the fill port may not be configured toprovide access to the interior volume of a filled container 1602, e.g.for pouring or drinking.

In some examples, one or more labels 1601 may be provided on theexterior of container 1602.

Container 1602 may optionally include a collar (not shown) as describedabove with respect to FIGS. 1 to 4. Additionally, or alternatively,container 1602 may include a lid (not shown) as described above withrespect to FIGS. 1 to 4 or FIG. 14. For example, container 1602 may becharacterized as a ‘ships-flat bottle with lid’. In some examples, thelid for container 1602 may be dimensioned to have an interior volumesimilar to that of a typical beverage container intended for personaluse, and to be graspable with one hand by a user. Such a lid may alsofunction as a cup, when removed from the container. The lid mayoptionally cover, seal, and/or protect the container 1602, or a portionof container 1602.

In some examples (not shown), container 1602 may be pleated to allow forgreater volume upon expansion.

In the example shown, the upper end cap 1614 is inclined. In alternativeexamples, the upper end cap may be flat.

Container 1602 may be disassembled and the separated components can thenbe recycled and/or composted. In some examples, container 1602 may beconfigured to be separable by hand. For example, after an end user hasemptied container 1602, the user may manually tear or otherwise separateliner layer 1610 from structural layer 1606, and recycle the former andcompost the latter.

Even if the components of container 1602 are not separated following itsuse, the container 1602 may be returned to a ‘flattened’ state, whichmay e.g. reduce its volume during transportation to and/or storage in alandfill or similar waste disposal facility.

Referring now to FIGS. 17A to 17B, an alternative example of a container1702 is shown. In FIGS. 17A to 17B, like features as in FIGS. 1 to 4 arereferred to with like reference numerals, with the first digitincremented by 16.

In this example, the container 1702 is a single use coffee pod. In sucha coffee pod, the interior of structural layer 1706 is filled withcoffee grounds, and optionally filter media 1711, as shown in FIG. 17A.Filter media 1711 may be in the form of an interior liner layer. Thecontainer 1702 also includes a lid portion 1713 made from a filtermedia. In some examples, the filter media/liner layer 1711 and lidportion 1713 may be integrally formed. Structural layer 1706 and itscontents are then sealed using exterior (or outer) liner layer 1710 andsecond liner layer 1712, as shown in FIG. 17B, which are pre-formedpolymeric liner layers.

In this example, container 1702 has an exterior (or outer) liner layer1710 provided on an exterior (or outer) surface of bowl-shapedstructural layer 1706. Liner layer 1710 is sealingly connected to asecond liner layer 1712, which in this example acts a lid for container1702. In some examples, exterior liner layer 1710 and second liner layer1712 may be integrally formed.

In use, hot water (or another suitable liquid) is introduced into theinterior of container 1702 by injecting through or otherwise piercingone or both of liner layers 1710, 1712. Once the hot water has mixed orotherwise reacted with the coffee grounds, brewed coffee is extractedthrough the same opening(s) in liner layers 1710, 1712 or through one ormore different openings.

In the example shown, a thread or other cord 1795 is positioned aboutsome or substantially all of the exterior of the upper end face 1726 ofthe structural layer 1706 of the container 1702. More specifically,thread 1795 is positioned within the seal between exterior liner layer1710 and second liner layer 1712. One or both free ends of thread 1795may be provided with a tab or other gripping surface 1796. In this way,a user can open container 1702 (e.g. after brewing) by pulling on thread1795. Since thread 1795 is positioned within the seal between the linerlayers 1710, 1712, continuing to pull on the thread 1795 acts toseparate liner layers 1710, 1712 from each other, facilitating theremoval of structural layer 1706 and/or its contents (e.g. used coffeegrounds and/or filter media) from the liner layers.

In some examples (not shown), one end of thread 1795 may be attached tostructural layer 1706. In this way, after thread 1795 has been pulled bya user to separate liner layers 1710, 1712 from each other, thread 1795may still be attached to structural layer 1706, further facilitating theremoval of structural layer 1706 and/or its contents (e.g. used coffeegrounds and/or filter media) from the liner layers 1710, 1712.

Preferably, thread 1795 is made of a natural and/or compostablematerial, such as cotton, jute, linen, hemp, and the like.

After separation, plant-based structural layer 1706 and/or its contentsmay be composted (e.g. in a home composter or via a municipal compostingprogram), while liner layers 1710, 1712 may be recycled or up-cycledseparately from the plant-based material.

By facilitating the separation of structural layer 1706 and/or itscontents (e.g. used coffee grounds and/or filter media) from the linerlayers, container 1702 may be more recyclable and/or compostable thantypical composite packaging material (e.g. as used in typical coffeepods), and/or may be otherwise regarded as a more environmentallyfriendly container.

In some examples container 1702 may be a single use coffee pod, sized tobrew a single cup of coffee. In other examples, container 1702 may besized to brew two or more cups of coffee, e.g. a carafe of coffee.Container 1702 may be used as a single use pod to brew or steepbeverages other than coffee (e.g. tea, hot chocolate, and the like), byproviding a suitable beverage concentrate, extract, or the like in thecontainer prior to the introduction of hot water (or another suitableliquid) into the interior of container 1702.

With liner layers 1710 and 1712 sealingly coupled to each other,container 1702 may be characterized as a fully-immersible container, asstructural layer 1706 is protected from moisture on its outer surfaces.Such a container may be useful, for example, for storing dry contents orother contents that may come into contact with structural layer 1706without damaging or otherwise reacting with structural layer 1706,and/or in environments where contact with moisture is expected, such asa kitchen counter.

In any of the above examples, the adhesive used may be a soy basedadhesive, a corn-based adhesive, a thermal adhesive, or another suitableadhesive. The adhesive used may be compatible with (e.g. able to adhereto) one or more materials. For example, a liner layer may be adhered toa structural layer using a single adhesive composition. The adhesive maybe provided on one or both of the layers to be adhered to each other asa tape, a coating, and/or any other suitable pattern (e.g. an array ofdiscontinuous dots).

As another example, a liner layer may be adhered to another liner layerusing an adhesive compatible with both liner layers. For example, wheretwo liner layers fabricated from a silicone polymer are being adhered toeach other, a silicone to silicone glue (e.g. silpoxy) may be used. Insome examples, one or more apertures or holes may be provided in astructural layer, and an adhesive may be provided in the apertures toallow two liner layers on opposite surfaces of the structural layer tobe adhered to each other (and also thereby secured to the structurallayer).

As another example, a structural layer may be adhered to anotherstructural layer using an adhesive compatible with both structurallayers. In some examples, one or more apertures or holes may be providedin a liner layer positioned between two structural layers, and anadhesive may be provided in the apertures to allow the two structurallayers to be adhered to each other (and also thereby securing the linerlayer between the structural layers). In any of the above examples,additional layers may optionally be applied to the container and/or thelid. For example, the container and/or the lid may include an innerliner layer of latex, as well as an outer liner layer of silicone.

For example, as shown in FIG. 18, an outer moisture-impermeable layer1890 may be applied to a lower portion of the container, acting as a‘boot’ or protective layer for containers placed on a wet surface.Alternatively, or additionally, an outer layer 1899 may be provided onthe exterior of a container in a position where a user is expected togrip or otherwise handle the container (e.g. as a strip, a band, or anyother suitable shape). For example, outer layer 1899 may act as amoisture and/or thermal barrier between the exterior surface of thecontainer and a user's hand. Alternatively, or additionally, outer layer1899 may be ribbed or otherwise textured to facilitate gripping of thecontainer by a user.

In any of the above examples, moisture-impermeable layers may beprovided on the interior and exterior surfaces of the container toprovide a fully-immersible (e.g. waterproof) container.

In any of the above examples, liner layers with a high thermal tolerancemay be provided on the interior and exterior surfaces of the containerto provide a heat resistant container. For example, a container (e.g. inthe shape of a tray) may include a fiber-based structural layercompletely enveloped by one or more layers of high-temperature siliconesuch that the container may be able to withstand long periods in an ovenat relatively high temperatures.

In any of the above examples, the structural layers may include aplurality of sub-layers. For example, the structural layer of thecontainers may include several sub-layers of thin bamboo plywood orbagasse paper. The sub-layers may optionally be adhered together withsoy or corn based adhesives, which may be applied between adjacentsub-layers, or mixed into the pulp of the sub-layers. In some examples,the structural layer may include an inner sub-layer made from a coarseand minimally refined fiber, and an outer layer made from a fine fiber.

In any of the above examples, the liner layers may include a pluralityof sub-layers. For example, the liner layer of the containers mayinclude a first sub-layer of a polymeric material, such as a siliconepolymer, latex, or a bioplastic, and a second sub-layer of a thin (or‘ultra-thin’) natural fiber. The sub-layers may optionally be adheredtogether with soy or corn based adhesives, which may be applied betweenadjacent sub-layers, or mixed into the pulp of the natural fibersub-layer.

In any of the above examples, a very thin layer of plant fiber (e.g.about the thickness of wrapping or tissue paper) may be provided on theexterior of the container. Such a thin layer of plant fiber may beprovided with a very thin coating of compostable soy or othercompostable plant based wax on the outside surface of the container.Providing such a thin waxed layer as a separate from the main structurallayer of fiber may facilitate the recycling of the main structurallayer, as the thin waxed layer may be removed prior to composting orrecycling the structural layer. (The thin waxed layer may be compostedseparately, as it may be difficult to process at typical recyclingfacilities). Alternatively, the thin waxed layer and the main structurallayer may be composted without separating the layers.

In any of the above examples, one the container and/or the lid mayoptionally include one or more handles. The handle(s) may optionally beintegrally formed with one of the structural layers.

In any of the above examples, the structural layer(s) may includeridges, corrugations, and/or other strengthening patterns.

In any of the above examples, food or other materials may be moldeddirectly in the container. For example, the container may be filled witha gelatin-based food in liquid form. The gelatin-based food may form toa semi-solid state in the container, and be molded to the shape of thecontainer. The gelatin-based food may then be removed from thecontainer, for example by inverting the container, and may retain theshape of the container. In further alternate examples, foods such asbaked goods may be cooked in the liner layer (optionally with the use ofa carrier). The liner layer, containing the cooked food, may then beinserted into and secured to the structural layer.

In further examples, the packages described herein may be used to finishfoods, such as cakes or other baked goods, as is described in PCTApplication No. PCT/CA2013/000443. For example a container describedabove may be partially filled with icing. A cake, having a volume thatis smaller than the volume of the container so that a gap exists betweenthe cake and the container, may then be pressed into the icing in thecontainer, so that the icing fills the gap between the cake and thecontainer. A lid may then be secured to the container, and the cake maybe shipped and/or stored and/or sold in the container. The iced cake maybe removed from the container.

The packages described herein may optionally be made in the form of, forexample, a bottle, a jar, a tube, a pouch, a box, a jug, a tube, or atray.

In any of the above examples, a soy based ink may optionally be appliedto the outer surface of the structural layer(s), in order to provideinformation or a decorative effect. Further, in any of the aboveexamples, a food grade shellac may be applied to the outer surface ofthe structural layer(s), to provide an aesthetic effect. Further, in anyof the above examples, a clay glaze may be applied to the outer surfaceof the structural layer. Some such materials may provide moistureresistance to the container.

In any of the above examples, an optional additional seal may beincluded on the container. For example, a foil seal may be appliedacross the opening 118, and may be adhered to the liner 110.

In any of the above examples, the packages and/or containers may be forshort-term use, or for long-term use. Packages and/or containers thatare intended for long-term use may in some examples have a relativelythick liner layer and/or a relatively thick support layer.

In any of the above examples, the package or container may be shipped ina flattened state. For example, the structural layer of the containermay be foldable into a flattened state, and the liner layer of thecontainer may be sufficiently flexible to be flattened. The structurallayers and liner layers may be secured together when flattened, or maybe separate. If separate, the structural layers and liner layers may beassembled and secured together after shipping, for example byun-flattening each layer, inserting the liner layer into the structurallayer, and securing the layers together.

In any of the above examples, the package or container may include anadditional gas impermeable layer, such as an oxygen impermeable layer.Such a layer may be separable from the other layers of the container.

In any of the above examples, the package or container may have atransparent panel for viewing its contents. For example, the structurallayer may have a cutout portion, and the liner layer may be transparent,so that the contents of the package or container can be viewed throughthe cutout.

An example method of manufacturing the containers described above willpresently be described. In order to manufacture the container 102, thestructural layer 106 may be formed from a plant based material, forexample by molding, as described above. The liner layer 110 may then beseparately formed, for example by molding the liner layer from apolymer, as described above. Alternatively, the liner layer may beformed on one or both sides of a thin carrier sheet, such as a thinsheet of plant based material.

The pre-formed liner layer 110 may then be mated with the structurallayer 106, for example inserted into the structural layer 106 so thatthe pre-formed liner layer 110 lines the structural layer 106. Inalternative examples, a structural layer may be inserted into a linerlayer.

The pre-formed liner layer 110 may then be secured to the structurallayer 106, for example may be removably secured with an adhesive or amechanical securing mechanism. As noted above, this may allow for thepre-formed liner layer 110 to be removed from the structural layer 106,and each of the pre-formed liner layer 110 and structural layer 106 maybe recycled.

In some examples, the method for securing the pre-formed liner layer 110to the structural layer 106 may involve the use of a separate piece,such as the collar 134, which may be secured over the liner layer 110.More specifically, as described above, an overlap portion 128 of thepre-formed liner layer may be positioned on an outer surface 122 of thestructural layer 106, and the threaded collar 134 may be positioned overthe overlap portion 128. The threaded collar 134 may then be adhered tothe structural layer 106 via apertures 135 in the overlap portion 128.

In some examples, the method for securing the pre-formed liner layer tothe structural layer may optionally include positioning a portion of thepre-formed liner layer between two portions of the structural layer, andpinching the portion of the pre-formed liner layer between the twoportions of the structural layer to frictionally secure the pre-formedliner layer to the structural layer, and/or adhering the two portions ofthe structural layer together via apertures in the portion of the linerlayer. For example, in the case of container 502, the tongue 558 may bepositioned in the groove 556 between opposed walls of the groove 556,and may be pinched between the opposed walls of the groove 556.Alternatively, in the case of container 702, the flanges 765, 767 of theliner layer 710 may be positioned between the flanges 764 a, 766 a ofthe first side piece 706 a and the flanges 764 b, 766 b of the secondside piece 706 b. The flanges 764 a, 766 a of the first side piece 706 amay then be adhered to the flanges 764 b, 766 b of the second side piece706 b, via apertures in the flanges 765, 767.

In some examples, the pre-formed liner layer may be modified after beingmated to and/or secured to the structural layer. Such modifications mayinclude heating or sonic welding to enhance water proofing or gasimpermeability, or to enhance the bond between the liner layer and thestructural layer.

While the above description provides examples of one or more processesor apparatuses, other processes or apparatuses may be within the scopeof the accompanying claims.

1. A package comprising: a) a container comprising a plant based firststructural layer having a first inner surface and an opposed first outersurface, and a pre-formed polymeric first liner layer secured to thefirst structural layer and lining at least one of a portion of the firstinner surface and a portion of the first outer surface; and b) a lidremovably securable to the container and comprising a plant based secondstructural layer having a second inner surface and an opposed secondouter surface, and a pre-formed polymeric second liner layer secured tothe second structural layer and lining at least one of a portion of thesecond inner surface and a portion of the second outer surface.
 2. Thepackage of claim 1, wherein the first liner layer is removably securedto the first structural layer, and the second liner layer is removablysecured to the second structural layer.
 3. The package of claim 1,wherein the first and second liner layers are secured to the first andsecond structural layers respectively with an adhesive.
 4. The packageof claim 1, wherein the first and second liner layers are mechanicallysecured to the first and second structural layers, respectively.
 5. Thepackage of claim 1, wherein the first structural layer comprises a baseand a first sidewall extending upwardly from the base, and defines afirst opening.
 6. The package of claim 5, wherein the first sidewall hasan upper end defining the first opening and comprising an upper endface, and wherein the first liner layer comprises an overlap portionthat includes a radially extending lip extending across the upper endface, and a downwardly extending first skirt extending along a portionof the first outer surface.
 7. The package of claim 6, furthercomprising a separately formed first collar for threadably securing thelid to the container, the first collar received around the overlapportion of the first liner layer, and having a threaded outercircumference for mating with the lid, wherein the first skirt has aplurality of apertures extending through a wall thickness thereof, andthe first collar is adhered to the first structural layer via theapertures.
 8. The package of claim 1, wherein: i) the second structurallayer comprises a top wall and a downwardly extending second side wall,and defines a second opening; ii) the second liner layer comprises adownwardly extending second skirt; and iii) the lid further comprises aseparately formed second collar for threadably securing the lid to thecontainer, the second collar received in the second skirt, and having athreaded inner circumference for mating with the container.
 9. Thepackage of claim 8, wherein the second skirt has a plurality ofapertures extending through a wall thickness thereof, and the secondcollar is adhered to the second structural layer via the apertures. 10.The package of claim 1, wherein: i) the first structural layer includesa first side piece, and a separately formed second side piece, each sidepiece comprising a base portion and a sidewall portion, and ii) eachsidewall portion comprises a pair of generally vertically extending endfaces and a pair of radially extending structural layer flanges adjacentthe end faces.
 11. The package of claim 10, wherein iii) the first linerlayer comprises a pair of liner layer flanges extending radiallyoutwardly therefrom, and each liner layer flange is sandwiched betweenone of the structural layer flanges of the first side piece and one ofthe structural layer flanges of the second side piece, and iv) the linerlayer flanges comprise a plurality of apertures extending through a wallthickness thereof, and the structural layer flanges of the first sidepiece are adhered to the structural layer flanges of the second sidepiece via the apertures.
 12. The package of claim 1, wherein the firstliner layer comprises a tongue, and the first structural layer comprisesa groove, and the tongue is received in the groove and is frictionallysecured therein.
 13. The package of claim 1, wherein at least one of thefirst liner layer and the second liner layer is fabricated fromsilicone.
 14. The package of claim 1, wherein at least one of the firststructural layer and the second structural layer is fabricated frombagasse.
 15. The package of claim 1, wherein the lid is removablysecurable to the container by screw-fit, snap-fit, bayonet mount, orfriction-fit.
 16. The package of claim 1, wherein the first liner layerand second liner layer are waterproof, antimicrobial, inert, and/or gasimpermeable.
 17. The package of claim 1, wherein the first liner layerdefines an interior volume that is sealed.
 18. The package of claim 1,wherein the first structural layer comprises a pair of flexible panels,each panel having a pair of opposed side edges, the pair of panels beingjoined to each other along the side edges, the container movable betweena flattened configuration in which the panels are flattened to provide asubstantially flat container, and an expanded configuration in which thepanels are flexed outwardly to define an interior volume of thecontainer therebetween.
 19. The package of claim 18, wherein the firststructural layer further comprises at least one end cap for retainingthe container in the expanded configuration
 20. The package of claim 1,wherein the container is pleated.
 21. The package of claim 1, whereinthe first structural layer and/or the second structural layer comprisesa plurality of sub-layers.